Systems and methods for applying dots of different adhesives to moving roofing shingle stock

ABSTRACT

Systems and methods of applying self-seal strips of multiple different adhesives are disclosed. In one embodiment, two spaced apart spoked applicator wheel assemblies are positioned beneath a web of moving shingle stock such that each of the applicator wheels applies dots of different adhesives in an alternating pattern. In other embodiments, a layer of a second adhesive is deposited onto previously applied dots of a first adhesive to form layered adhesive dots with dual properties of both adhesives.

REFERENCE TO RELATED APPLICATION

The present Patent application claims the benefit of U.S. ProvisionalApplication No. 62/985,607, filed Mar. 5, 2020.

INCORPORATION BY REFERENCE

The disclosures made in U.S. Provisional Application No. 62/985,607,filed Mar. 5, 2020, are specifically incorporated by reference herein asif set forth in their entirety.

TECHNICAL FIELD

This disclosure relates generally to roofing shingle manufacturing andmore specifically to the application of self-seal strips to a moving webof roofing shingle stock.

BACKGROUND

Self-seal strips of adhesive commonly are applied to shingle stock asthe stock is conveyed along a manufacturing path. Self-seal stripstypically comprise lines or linear arrays of adhesive dots separated byspaces. A need exists for applying self-seal strips comprisingalternating dots of different adhesives with different tackingtemperatures (or other properties) at higher line speeds. A need alsoexists for more effective application of a second different adhesivelayer onto previously applied adhesive dots of a first adhesive to formmulti-layer adhesive dots with dual properties, again at higher linespeeds. It is to the provision of systems and methods that meet theseand other needs that the present disclosure is primarily directed.

SUMMARY

Briefly described, a system and method are disclosed for applying aself-seal strip of adhesive materials comprising alternating dots ofdifferent adhesives that have different adhesive properties to a shinglestock. For example, different adhesives having different adhesiveproperties such as an ability to tack at different temperatures or otherdifferent properties can be applied. In embodiments, two applicatorassemblies are disposed beneath the moving shingle stock, the secondapplicator assembly being downstream of the first applicator assembly.The first applicator assembly includes a first applicator wheel thatapplies a linear array of adhesive dots of a first adhesive material,with spaces between the dots of the first adhesive. In some embodiments,the second applicator assembly can include a second applicator wheelsynchronized with the first applicator wheel so that it applies a secondarray of adhesive dots of a second, different adhesive material to themoving shingle stock within the spaces between the dots of the lineararray of first adhesive dots. Other patterns of application of the firstand second adhesives also can be provided. The applicator wheels canoperate at higher rotation rates to accommodate higher line speeds.

Also disclosed are systems and methods of applying a second, differentadhesive onto previously applied dots of a first adhesive as roofingshingle stock moves along a processing path. In one embodiment, a secondapplicator assembly is adjusted so that adhesive coated portions thereofjust kiss previously applied adhesive dots of the first adhesive todeposit the second adhesive thereon. In another embodiment, an adhesivedie is disposed beneath the moving shingle stock, aligned withpreviously applied dots of a first adhesive being carried by the movingshingle stock. The second, different adhesive is pumped through the dieso that a small puddle of the second adhesive is maintained atop thedie. The previously applied first adhesive dots move through the puddleand pick up a layer of the second adhesive to form multi-adhesive dots,which define seal-seal strips for shingles or other roofing materialsformed from the shingle stock.

Various aspects of the present disclosure further include, withoutlimitation, a system comprising a conveyance system for conveying a webof shingle stock along a path; a first applicator assembly positionedalong the path of the web of shingle stock, the first applicatorassembly configured to apply a linear array of dots of a first adhesiveto the web of shingle stock; and a second applicator assembly positionedalong the path of the web of shingle stock downstream from the firstapplicator assembly, the second applicator assembly configured to applya second adhesive to the web of shingle stock along the linear array ofdots of the first adhesive. In some embodiments, the first adhesivecomprises a self-seal adhesive material having first adhesive propertiesand the second adhesive comprises a self-seal adhesive having secondadhesive properties that are different from the first adhesiveproperties of the first adhesive. The application of the first adhesiveand the second adhesive forms a multi-adhesive self-seal strip havingdifferent adhesive properties along the web of shingle stock.

In some embodiments, the system further comprises a stabilizer assemblylocated along the path of the web of shingle stock. In some embodiments,the stabilizer assembly includes a stabilizer wheel on one side of theweb of shingle stock and aligned opposing supports on another side ofthe web of shingle stock. In other embodiments, the stabilizer assemblycan comprise a stabilizer wheel under which the web of shingle stocktravels, flanked by a plurality of rollers over which the web of shinglestock travels.

In some embodiments of the system, the first applicator assemblycomprises a first applicator wheel having a plurality of spokesconfigured to apply the dots of the first adhesive, and the secondapplicator assembly comprises a second applicator wheel configured torotate in synchronization with the first applicator wheel to apply thesecond adhesive to the web of shingle stock between the dots of thefirst adhesive applied to the web of shingle stock by the firstapplicator assembly.

In other embodiments of the system, the first applicator assemblycomprises a first applicator wheel having a plurality of spokesconfigured to apply the dots of the first adhesive, and the secondapplicator assembly comprises a second applicator wheel configured torotate in synchronization with the first applicator wheel to apply thesecond adhesive to the web of shingle stock along the dots of the firstadhesive applied to the web of shingle stock by the first applicatorassembly.

In further embodiments of the system, the second applicator assemblycomprises a puddle die in communication with an adhesive supply, thepuddle die including a top portion configured to maintain a puddle ofthe second adhesive in a position adjacent the web of shingle stock suchthat the dots of the first adhesive engage the puddle of the secondadhesive to pick up a layer of the second adhesive as the dots of thefirst adhesive pass along the puddle die.

In embodiments, the first applicator assembly can comprise an applicatorwheel having a plurality of spokes and an adhesive die configured todeposit the first adhesive onto each of the spokes of the applicatorwheel. In still other embodiments of the system, the second applicatorassembly can comprise an applicator wheel having a plurality of spokesand an adhesive die configured to deposit the second adhesive onto eachof the spokes of the applicator wheel.

In some embodiments, the first applicator assembly comprises a firstapplicator wheel and the second applicator assembly comprises a secondapplicator wheel. The first applicator wheel, the second applicatorwheel, or both, also are heated to a temperature sufficient to maintainthe first adhesive in a liquid state.

In still other embodiments of the system, the second adhesive comprisesan adhesive material configured to exhibit a high tacking under coldweather conditions and the first adhesive comprises an adhesive materialconfigured to form a seal following exposure to sunlight and heat.

In other aspects of the present disclosure, a method is provided. Inembodiments, the method, comprises moving a web of shingle stock along apath; first, applying a first adhesive to a surface of the web ofshingle stock using a first applicator assembly; and second, applying asecond adhesive along the web of shingle stock. In embodiments, thefirst adhesive and the second adhesive each comprise a self-sealadhesive material having different, cooperative adhesive properties; andthe first adhesive and the second adhesive are applied to the surface ofthe web of shingle stock so as to form a self-seal strip along the webof shingle stock.

In embodiments of the method, the first applying step comprises applyingdots of the first adhesive. In addition, in embodiments, the secondapplying step comprises applying dots of the second adhesive withinspaces defined between the first adhesive previously applied to the webof shingle stock.

In some embodiments, the second applying step comprises applying thesecond adhesive onto the dots of the first adhesive previously appliedto the web of shingle stock.

In still other embodiments, the second applying step comprises applyingdots of the second adhesive at locations spaced in a cross-wisedirection across the web of shingle stock from the dots of the firstadhesive.

In some embodiments of the method, the second applying step comprisesmoving the dots of the first adhesive applied to the web of shinglestock along a second applicator assembly and picking up a layer of thesecond adhesive along the dots of the first adhesive.

In some embodiments, the second applicator assembly comprises a puddledie configured to maintain a puddle of the second adhesive in a positionadjacent the web of shingle stock, and moving the dots of the firstadhesive applied to the web of shingle stock along the second applicatorassembly further comprises moving the dots of the first adhesive throughthe puddle of the second adhesive.

In still other embodiments of the method, the first applicator assemblycomprises a first applicator wheel, and the first applying stepcomprises applying the first adhesive to a surface of the firstapplicator wheel and rotating the surface of the first applicator wheelwith the first adhesive applied thereto into engagement with the surfaceof the web of shingle stock.

In embodiments, the second applicator assembly comprises a secondapplicator wheel, and the second applying step comprises moving the webof shingle stock with the dots of the first adhesive applied theretopast the second applicator wheel, and rotating the second applicatorwheel in synchronization with the first applicator wheel to apply dotsof the second adhesive to the web of shingle stock along spaces betweenthe dots of the first adhesive applied to the web of shingle stock bythe first applicator wheel.

In other embodiments, the second applicator assembly comprises a secondapplicator wheel, and wherein the second applying step comprises movingthe web of shingle stock with the dots of the first adhesive appliedthereto past the second applicator wheel, and rotating the secondapplicator wheel in synchronization with the first applicator wheel toapply the second adhesive to the web of shingle stock on the dots of thefirst adhesive applied to the web of shingle stock by the firstapplicator wheel.

Thus, embodiments of systems and methods for application of sealantadhesive materials to a shingle stock material, which can include theapplication of different adhesives materials selected to providedifferent, synergistic or cooperative properties, are disclosed that aredirected to the above discussed and other needs. The foregoing and otheradvantages and aspects of the embodiments of the present disclosure willbecome apparent and more readily appreciated from the following detaileddescription and the claims, taken in conjunction with the accompanyingdrawings. Moreover, it is to be understood that both the foregoingsummary of the disclosure and the following detailed description areexemplary and intended to provide further explanation without limitingthe scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the embodiments of the present disclosure, areincorporated in and constitute a part of this specification, illustrateembodiments of this disclosure, and together with the detaileddescription, serve to explain the principles of the embodimentsdiscussed herein. No attempt is made to show structural details of thisdisclosure in more detail than may be necessary for a fundamentalunderstanding of the exemplary embodiments discussed herein and thevarious ways in which they may be practiced.

FIG. 1 is a side elevational view of an embodiment of a system forapplying a self-seal strip comprising alternating dots of differentadhesives to moving web of roofing shingle stock to form a self-sealstrip of multi-adhesive, multi-property dots according to principles ofthe present disclosure.

FIG. 2 is a side elevational view of another embodiment of a system forapplying a second, different adhesive onto previously applied firstadhesive dots to form a self-seal strip of multi-adhesive,multi-property dots according to principles of the present disclosure.

FIG. 3 is a rear elevational view of the system depicted in FIG. 2 .

FIG. 4 is a side elevational view of another embodiment of a system forapplying a second, different adhesive onto previously applied firstadhesive dots to form a self-seal strip of multi-adhesive,multi-property dots according to principles of the present disclosure.

FIG. 5 is a side elevational view of an alternate embodiment of a systemfor applying a second, different adhesive onto previously applied firstadhesive dots to form a self-seal strip of multi-adhesive,multi-property dots according to principles of the present disclosure.

FIG. 6 is a rear elevational view of the system depicted in FIG. 5

DETAILED DESCRIPTION

FIG. 1 depicts a web of shingle stock 11 moving along a path in aprocessing direction 12 during manufacture, with the moving web ofshingle stock 11 carried along its path by rollers or other conveyancesystem. In the embodiment shown in FIG. 1 , a pair of applicatorassemblies are arranged along the paths of travel of the moving web ofshingle stock 11, including a first applicator wheel assembly 13disposed beneath the moving shingle stock. A second applicator wheelassembly 14 is disposed beneath the moving shingle stock downstream ofthe first applicator wheel assembly 13. Each applicator wheel assemblymay be similar to the applicator wheel assembly disclosed in U.S. Pat.No. 10,195,640 owned by the present applicant, the contents of which arehereby incorporated by reference. Generally speaking, the firstapplicator wheel assembly 13 includes a spoked first applicator wheel 16mounted for rotation in a direction indicated by arrow 17. The secondapplicator wheel assembly 14 generally will have a similarly spokedsecond applicator wheel 26 that rotates in a direction indicated byarrow 27. The depicted first and second applicator wheels further areshown with five spokes, but applicator wheels with more or fewer spokesalso are possible within the scope of the present disclosure.

For example, in some embodiments, each applicator wheel has 1 to 10spokes. In other embodiments, each applicator wheel has 1 to 9 spokes.In other embodiments, each applicator wheel has 1 to 8 spokes. In otherembodiments, each applicator wheel has 1 to 7 spokes. In otherembodiments, each applicator wheel has 1 to 6 spokes. In other 5embodiments, each applicator wheel has 1 to 5 spokes. In otherembodiments, each applicator wheel has 1 to 4 spokes. In otherembodiments, each applicator wheel has 1 to 3 spokes. In otherembodiments, each applicator wheel has 1 to 2 spokes. In otherembodiments, each applicator wheel has 2 to 10 spokes. In otherembodiments, each applicator wheel has 3 to 10 spokes. In otherembodiments, each applicator wheel has 4 to 10 spokes. In otherembodiments, each applicator wheel has 5 to 10 spokes. In otherembodiments, each applicator wheel has 6 to 10 spokes. In otherembodiments, each applicator wheel has 7 to 10 spokes. In otherembodiments, each applicator wheel has 8 to 10 spokes. In otherembodiments, each applicator wheel has 6 to 10 spokes. In otherembodiments, each applicator wheel has 2 to 9 spokes. In otherembodiments, the applicator wheel has 3 to 8 spokes. In otherembodiments, each applicator wheel has 4 to 7 spokes. In otherembodiments, each applicator wheel has 5 to 6 spokes. In otherembodiments, each applicator wheel has 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10spokes. In yet other embodiments, each applicator wheel has 10 to 20spokes. In some embodiments, the number of spokes is based on a diameterof each applicator wheel, and can be different for each applicatorwheel.

In some embodiments, the diameter of each applicator wheel is 12 inchesto 42 inches. In some embodiments, the diameter of each applicator wheelis 16 inches to 42 inches. In some embodiments, the diameter of eachapplicator wheel is 20 inches to 42 inches. In some embodiments, thediameter of each applicator wheel is 24 inches to 42 inches. In someembodiments, the diameter of each applicator wheel is 30 inches to 42inches. In some embodiments, the diameter of each applicator wheel is 36inches to 42 inches. In some embodiments, the diameter of eachapplicator wheel is 12 inches to 36 inches. In some embodiments, thediameter of each applicator wheel is 12 inches to 30 5 inches. In someembodiments, the diameter of each applicator wheel is 12 inches to 24inches. In some embodiments, the diameter of each applicator wheel is 12inches to 20 inches. In some embodiments, the diameter of eachapplicator wheel is 12 inches to 16 inches. In some embodiments, thediameter of each applicator wheel is 16 inches to 36 inches. In someembodiments, the diameter of each applicator wheel is 20 inches to 10inches. In some embodiments, the diameter of each applicator wheel is12, 16, 20, 24, 30, 36, or 42 inches. In embodiments, the diameter ofeach applicator wheel further can be substantially equal to twice thedistance from the center of each applicator wheel to the tip of a spoke.

In embodiments, each applicator wheel is comprised of steel and will beheated to help maintain the adhesive materials in the substantiallyliquid state during and after engagement of the applicator wheels withthe shingle stock. In embodiments, each applicator wheel is heated byhot oil and/or electric heating. In yet other embodiments, eachapplicator wheel assembly 13/14 further is equipped with a scraper 15/30that is configured to remove residual adhesive from the applicator wheelbetween adhesive applications. For example, in embodiments, the scrapers15/30 can comprise blades or strips of a material such as high densitypolyethylene (HDPE), Teflon® (polytetrafluoroethylene), or a metalcoated with a non-stick material. The scrapers can have a flexibilityand/or be mounted so as to be biased into engagement with the lands ofthe spokes of the applicator wheels in a manner sufficient to scrape offresidual adhesive and provide a substantially clean surface to the landsas they approach the adhesive dies 22/32. Such clearing of the remainingor residual adhesive materials from the surfaces of the lands of theapplicator wheels helps enable a more consistent application of theadhesive materials thereto. Multiple scrapers also can be used atdifferent locations about each applicator wheel.

Embodiments of the present disclosure further can enable a reduction inthe size of the applicator wheel(s) due to the application of adhesiveclose to the point of contact with the shingle stock. The use ofapplicator wheels of a smaller size or which have spokes or lands with areduced surface area or size, and heating of the applicator wheelsfurther can serve to help dislodge and propel excess adhesive notapplied to the shingle stock to a return chamber 18/28 for feeding backto the adhesive supply to be reused.

The applicator wheel 16 rotates so that the peripheral surfaces of itsspokes 16 a move at the line speed of the shingle stock 11 (or at somemultiple of the line speed or some different speed). As shown in FIG. 1, the lands 16 b of the spokes 16 a are rotated upwardly and engage thebottom surface of the shingle stock 11. An adhesive die 22 is mountedadjacent the first applicator wheel 16. The adhesive die is configuredto eject a stream of a first adhesive 23 fed from a supply onto the land16 b of each spoke 16 a just before the spoke engages a side surface ofthe shingle stock 11. In various embodiments, the first adhesive 23 isdeposited onto the shingle stock as each spoke engages the stock to forma linear array or pattern of first adhesive dots 24 along the length ofthe shingle stock. It will be understood that the term “dots” is not tobe taken as limiting as to a size or configuration of the appliedadhesive materials, and can include lines, strips, layers and/or otheradhesive applications for forming self-seal adhesive strips. The firstadhesive dots are separated by gaps or spaces 25 that can vary in sizebased on a size of the first adhesive dots 24, rate of movement of theshingle stock, applicator wheel speed, and potentially other factors.

The first applicator wheel 16 further rotates within a heated returnchamber 18 that captures any adhesive that may be slung or drip off ofthe first applicator wheel as it rotates through its return chamber 18.A heated return conduit 19 delivers the captured adhesive back to asupply, where it is re-used for supplying the die 22. The firstapplicator wheel assembly 13 further may include a surrounding supportstructure 21 within which the first applicator wheel, return chamber,and die are disposed.

The second applicator wheel assembly 14 can have a constructionsubstantially the same as the first applicator wheel assembly 13, exceptthat it applies a second, different adhesive to the moving web ofshingle stock 11 being conveyed thereabove. The second adhesivegenerally can be selected to have different yet cooperative orsynergistic properties compared to the first adhesive, such as having adifferent tacking temperature than the first adhesive. The two adhesivesalso may have properties other than tacking temperature that aredifferent.

As illustrated in FIG. 1 , the second applicator wheel assembly 14includes a heated rotating applicator wheel 26, shown with five spokes26 a that terminate at lands 26 b along which the second adhesive isapplied, and rotating in direction 27. The second applicator wheel 26 isshown in FIG. 1 as rotating in the same direction 27 as the direction ofrotation 17 of the first applicator or wheel 16, but also can be rotatedin an opposite direction to the direction of rotation of the firstapplicator wheel. A die 32 is fed with a flow of second adhesive from asupply, which second adhesive is ejected onto the lands of the spokes ofthe second applicator wheel 26. The second applicator wheel assembly 14,like the first applicator wheel assembly 13, also includes a returnchamber 28 and a return conduit 29 that can be heated, one or morescrapers 30, and may be mounted within a support structure 31.

In embodiments, rotation of the second applicator wheel 26 issynchronized with rotation of the first applicator wheel 16 so that thesecond applicator wheel 26 deposits dots 34 of the second adhesive alongthe shingle stock 11 in the spaces 25 between dots 24 of the firstadhesive. In other embodiments, the rotation of the second applicatorwheel 26 is synchronized to apply dots of the second adhesive in otherlocations, including adjacent or along the dots 24 of the firstadhesive. Synchronization of the first and second applicator wheels16/26 may be accomplished in any appropriate manner such as, forexample, mechanical gearing or electronic synchronization of drivemotors by a controller among others. The ultimate result is theapplication of a self-seal strip to the shingle stock with differentadhesives applied in a desired pattern that can consist of alternatingdots of different adhesive materials having different tackingtemperatures and/or other properties.

In embodiments, the second adhesive can include a self-seal adhesivematerial with a higher tackiness or an ability to adhere in colderweather or otherwise provide more aggressive engagement than the firstadhesive (which can have a less aggressive engagement or tacking butprovide a more permanent hold), and can be applied in a lesser orreduced amount compared to the application of the first adhesive. Thesecond adhesive also can be applied in a ratio with respect to the firstadhesive material of 1 to 4 or 1 to 3, or 1 to 2 or in otherapplications can be applied in a ratio 2 to 3. Each applicator wheelassembly also can operate at line speeds above speeds of 800 feet perminute, enabling the multi-adhesive self-seal strip to be applied athigh line speeds with the system of FIG. 1 .

The first and second adhesives 23 and 33 further can be applied invarying patterns or configurations along the surface of the moving webof shingle stock 11. For example, as noted above and as indicated inFIG. 1 , the first and second adhesives can be applied in analternating, “ABAB” type of pattern, with dots 24 of the first adhesive23 (the “A” adhesive) alternating with dots 34 of the second adhesive 33(the “B” adhesive). In other embodiments, other application patterns ofthe first and second adhesives can be provided, such as by varying thenumber of spokes of the first and second applicator wheels 16 and 26and/or the speed of rotation the first and/or second applicator wheelsto apply multiple dots of the first and/or second adhesives to themoving web of shingle stock. By way of example and not limitation, thefirst applicator wheel can be provided with additional spokes 16 aand/or can be operated at a higher rate of rotation to apply more thanone dot or strip of the first adhesive material to the moving web orshingle stock, while the second applicator wheel 26 can be provided withthe same or different numbers of spokes 26 a and/or can be operated at asimilar or different rate of rotation than the first applicator wheel,to form an AAB, AAAB, an AABB or BBA patterns of the first and secondadhesive dots along the web of shingle stock. Thus, the presentdisclosure is not limited simply to the application of the first andsecond adhesives in particular pattern, such as an ABAB type pattern.

Still further, in addition to the varying numbers of spokes of the firstand second applicator wheels and controlling the rates of rotation ofthe first and/or second applicator wheels, the size and/or configurationof the lands 16 b/26 b of the spokes 16 a/26 a of the first and secondapplicator wheels 16/26 also can be varied to thus vary the size, shapeand/or configurations of the adhesive dots applied to the moving web ofshingle stock.

In still other embodiments, the first and second applicator wheelassemblies can be arranged along the path of the moving web of shinglestock 11 at varying locations, including being positioned at offset ormisaligned locations. With such an offset alignment, the first andsecond adhesives can be applied to the moving web of shingle stock inoffset lines or dots. By way of example, in one embodiment, the firstand second applicator wheels can be arranged at different spacing's froma peripheral edge of the moving web of shingle stock, resulting inapplication of dots of the first and second adhesives at locations orpositions laterally spaced across the shingle stock from one another.The applicator wheels also can have a reduced thickness such that, witha lateral spacing of, for example, approximately 3/16 of an inch apart,the dots of the first and second adhesives together can form a self-sealstrip of a desired thickness, length and width, e.g., a self-seal stripcovering ⅜ of an inch.

In still other embodiments, the first and second applicator wheels andcan be arranged in a Z or cross-wise direction with respect to the pathor processing path 12 of the moving web of shingle stock 11. In such anarrangement, the first and second adhesives can be applied to the movingweb of shingle stock in a pattern whereby dots of the first adhesive arespaced inwardly from the peripheral edge of the shingle stock, and thesecond adhesive can be applied as dots offset cross-wise from andaligned with the spaces between the dots 24 of the first adhesive, oralong the dots 24 of the first adhesive, between the first adhesive dotsand the peripheral edge of the shingle stock.

In applications, the first and second adhesive materials will comprisedifferent self-seal adhesive materials that typically will havedifferent properties. The first and second adhesives further generallywill be selected to provide different but complimentary, cooperativeand/or synergistic properties and actions. For example, in embodiments,the second adhesive can be selected to provide an increased or higherlevel of tackiness or more aggressive hold or engagement, particularlyunder colder weather conditions, while the first adhesive can includeself-seal adhesive materials that have a lower level or degree oftackiness and/or less compressibility, but which, after exposure to sunand heat, generally will form a more permanent seal or engagement of theshingles with a roof deck. As a result, roofing materials such asshingles can be formed with self-seal strips whereupon, when applied toa roof deck, the higher tacking second adhesives can engage and helphold the shingles against the roof deck, providing enhanced resistanceto wind, as the first adhesives become fully sealed. The systems andmethods of application of the first and second adhesives according tothe principles of the present disclosure thus enable the application ofdifferent self-sealing adhesive materials to a moving web of shinglestock, with the first adhesive having first adhesive properties, whilethe second adhesive can have second adhesive properties that differ fromthe first adhesive properties, resulting in the formation of shingles orother roofing materials with multi-adhesive, multi-property self-sealstrips; and which enables a balancing of synergetic or cooperativeproperties of different self-seal adhesives, including balancing cost,cold weather applications versus hot weather, different tacking, and/orother properties.

Another way to realize the benefits of two different adhesives in aself-seal strip is to apply a layer of a second adhesive onto thesurface of dots made of a first adhesive. FIGS. 2 and 3 illustrate anembodiment of a system and method of accomplishing this at higher linespeeds. Referring to both figures, a web 41 of shingle stock 11 isconveyed along a path in a processing direction 42. In this embodiment,adhesive dots 43 of a first adhesive material are shown havingpreviously been applied to the shingle stock by a first applicatorassembly at an upstream location. The first applicator assembly may, forexample, be an apparatus such as that previously described. The shinglestock and linear array of first adhesive dots are conveyed to a secondapplicator assembly 44 having a heated sump or pan 46 carrying a supplyof second adhesive 47 and an applicator wheel 48.

The applicator wheel 48 is shown rotating in a direction 51 and movesthrough the supply of second adhesive 47 at the bottom of its rotation.The applicator wheel 48 has a peripheral surface 45 configured to pickup a layer of second adhesive on its peripheral surface and, as itrotates, will carry this layer up and toward the moving shingle stockabove. While the applicator wheel 48 is shown rotating in a directionindicated by arrow 51, the applicator wheel 48 also can be rotated in anopposite direction for application of the second adhesive.

A scraper fork 52 positioned adjacent the applicator wheel, and isadjustable with respect to the peripheral surface of the applicatorwheel by an adjustment 53 mechanism (e.g., a biasing member) to scrapeoff excess adhesive from the peripheral surface 45 of the applicatorwheel 48, leaving a desired substantially uniformly thick coating. Theapplicator wheel generally is heated and is mounted on an adjustableshaft mechanism 49 so that it can be finely adjusted in the verticaldirection so as to just kiss the surfaces of the previously applied dots43 of the first adhesive without touching the shingle stock. Astabilizing assembly that includes a stabilizing roller 54 rotating indirection 50 in conjunction with underlying guides 56 stabilizes thevertical position of the shingle stock and the previously applied dots43 of the first adhesive as they pass the applicator wheel assembly 44.

As each of the previously applied dots of the first adhesive 43 iskissed by the peripheral surface of the applicator wheel 48, a layer 57of the second adhesive is transferred from the applicator wheel 48 ontoeach of the dots of first adhesive. Each of the previously applied dotsof the first adhesive further generally will be cooled, such as bypassing the web of shingle stock through a cooler, by fans, or othercooling device to solidify the first adhesive dots to an extentsufficient to enable application of the second adhesive thereto. Thisforms a multi-layer adhesive dot having properties of both adhesives.For instance, where the adhesives have different tacking temperatures,one of the adhesives may quickly tack to an underlying shingle wheninstalled and at a lower temperature, whereas the other may act tocomplete the adhesive bond when the temperature rises. FIG. 3illustrates a stabilizing assembly comprising the stabilizing wheel 54and guides 56 that stabilize the shingle stock and the dots of firstadhesive 43 as the layer of second adhesive 57 is applied onto thepreviously applied dots of the first adhesive.

FIG. 4 illustrates an embodiment of another alternative system forstabilizing the shingle stock and positioning the existing adhesive dotsfor application of the layer of second adhesive. Here, an applicatorwheel assembly as shown in the embodiment of FIGS. 2 and 3 can be used.For stabilization, the web of shingle stock 66 passes over an upstreamgrooved relief roller 69, under a main stabilizer wheel 68, and over adownstream grooved relief roller 72. The roller 69, the stabilizer wheel68 and the roller 72 forming a stabilizer assembly. The moving web ofshingle stock 66 has a linear array of previously applied dots 67 of afirst adhesive. The grooved relief rollers 68 and 72 are formed withrelief grooves 71 and 73 respectively through which the previouslyapplied adhesive dots pass to avoid getting smashed. The rollers 69 and72 tension the shingle stock as it moves below the main stabilizer wheel68, being directed downwardly toward engagement with the applicatorwheel assembly 46.

The applicator wheel assembly 46 is adjusted as described above so thatthe peripheral surface of its applicator wheel 48 just kisses each ofthe existing dots of first adhesive without touching the shingle stock.And, as in the previous embodiment, a layer of a second adhesive 74 isdeposited onto the surface of each of the existing previously applieddots of first adhesive to create multi-layer adhesive dots each withdual properties, such as dual tacking temperatures, for example.

FIGS. 5 and 6 illustrate yet another embodiment of a system and methodfor creating roofing materials such as shingles with applied self-sealstrips comprising multi-layer dual function adhesive dots. In thisembodiment, the stabilization system is substantially the same asdescribed above relative to FIG. 4 . The system includes two groovedrelief rollers 86 and 87 having relief grooves 87 and 89 and a mainstabilization wheel 84. The shingle stock 81 with previously appliedadhesive dots 83 pass in direction 82 over rollers 86 and 88 and underthe main stabilizer wheel 84.

In this embodiment, a puddle die 91 is disposed beneath the mainstabilizer wheel 84 and is supplied through supply conduit 93 with thesecond adhesive from supply 92. The second adhesive is supplied to thepuddle die 91 under controllable pressure. The pressure is controlled sothat a small puddle 94 of the second adhesive is maintained on the topportion of the puddle die. The vertical position of the puddle die iscarefully adjusted so that the puddle does not engage the shingle stock.As the previously applied dots of first adhesive 83 pass just above thepuddle die, they are dragged through the standing puddle of secondadhesive 94. As a result, a layer of the second adhesive is picked up bythe previously applied dots of first adhesive forming multi-layer dotsof the first adhesive 83 and the second adhesive 96.

In FIG. 6 , the puddle die 91 has an internal cavity 97 through whichthe second adhesive moves before exiting at the mouth of the puddle dieto form the puddle 94 of second adhesive. The pressure at which thesecond adhesive is delivered to the puddle die can be calibrated tomaintain the puddle of adhesive at a predetermined desired thickness of1 to 10 mils. as layers of the second adhesive are picked up by thepreviously applied dots of first adhesive 83. In some embodiments, thepuddle die can be calibrated to maintain a puddle of adhesive at athickness of 0.5 to 15 mils; 1 to 15 mils; 1 to 10 mils; 1 to 9 mils; 1to 8 mils; 1 to 7 mils; 1 to 6 mils; 1 to 5 mils; 1 to 4 mils; 1 to 3mils; 1 to 2 mils; 0.5 to 1 mils; and/or other thicknesses. In yet otherembodiments, the puddle die can be calibrated to maintain a puddle ofadhesive at a thickness of 2 to 15 mils; 3 to 15 mils; 5 to 10 mils; 7to 10 mils; 9 to 10 mils; 3 to 10 mils; 5 to 15 mils; 7 to 15 mils; 10to 15 mils; 12 to 15 mils; 14 to 15 mils; and/or other thicknesses. Thedelivery of adhesive to the die further can be adjusted to deliver apartial amount of adhesive to the beginning of the first dot and leavethe first dot only partially covered by the second adhesive, allowing apartial exposure of both adhesives to the shingle material below duringinstallation.

The foregoing description generally illustrates and describes variousembodiments of the present disclosure. It will, however, be understoodby those skilled in the art that various changes and modifications canbe made to the above-discussed construction of the present disclosurewithout departing from the spirit and scope of the disclosure asdisclosed herein, and that it is intended that all matter contained inthe above description or shown in the accompanying drawings shall beinterpreted as being illustrative, and not to be taken in a limitingsense. Furthermore, the scope of the present disclosure shall beconstrued to cover various modifications, combinations, additions,alterations, etc., above and to the above-described embodiments, whichshall be considered to be within the scope of the present disclosure.Accordingly, various features and characteristics of the presentdisclosure as discussed herein may be selectively interchanged andapplied to other illustrated and non-illustrated embodiments of thedisclosure, and numerous variations, modifications, and additionsfurther can be made thereto without departing from the spirit and scopeof the present disclosure as set forth in the appended claims.

The invention claimed is:
 1. A roofing material comprising: a shingleformed from a shingle stock material and comprising: a first pluralityof dots of a first adhesive applied along a surface of the shingle; anda second plurality of dots of a second adhesive applied along thesurface of the shingle; wherein the first plurality of dots of the firstadhesive are non-overlapping with the second plurality of dots of thesecond adhesive; wherein the first adhesive comprises a self-sealadhesive material having first adhesive properties and the secondadhesive comprises another self-seal adhesive material having secondadhesive properties that are different from the first adhesiveproperties of the first adhesive such that application of the firstadhesive and the second adhesive forms a multi-adhesive self-seal striphaving different adhesive properties along the surface of the shingle;wherein the self-seal adhesive material of the second adhesive isconfigured to exhibit tacking at a tacking temperature that is less thana tacking temperature of the self-seal adhesive material of the firstadhesive; and the self-seal adhesive material of the first adhesive isconfigured to form a seal following exposure to sunlight or heat, andwherein an amount of the second plurality of dots of the second adhesiveis less than an amount of the first plurality of dots of the firstadhesive, such that the second plurality of dots of the second adhesiveare applied to the surface of the shingle in a ratio with respect to thefirst plurality of dots of the first adhesive of 1 to 4, 1 to 3, 1 to 2,2 to 3 or 3 to
 4. 2. The roofing material of claim 1, wherein the secondplurality of dots of the second adhesive are applied along spacesdefined between the first plurality of dots of the first adhesiveapplied along the surface of the shingle.
 3. The roofing material ofclaim 1, wherein the first and second adhesives are applied in varyingpatterns or configurations along the surface of the shingle stock. 4.The roofing material of claim 1, wherein the first and second adhesivesare applied in varying patterns or configurations whereby the firstplurality of dots of the first adhesive are spaced inwardly from aperipheral edge of the shingle, and the second plurality of dots of thesecond adhesive are applied at positions offset cross-wise from andaligned with spaces between the first plurality of dots of the firstadhesive, along the first plurality of dots of the first adhesive,between the first plurality of dots of the first adhesive and theperipheral edge of the shingle, or combinations thereof.
 5. The roofingmaterial of claim 1, wherein the first and second adhesives are appliedin a pattern or configuration of dots of the first plurality of dotsalternating with dots of the second plurality of dots along the surfaceof the shingle stock.
 6. The roofing material of claim 1, wherein thefirst and second adhesives are applied in a pattern or configuration oftwo or more dots of the first plurality of dots and at least one dot ofthe second plurality of dots along the surface of the shingle stock. 7.The roofing material of claim 1, wherein the first and second adhesivesare applied in patterns or configurations along the surface of theshingle stock; the patterns or configurations including two or more dotsof the first plurality of dots alternating with one or two dots of thesecond plurality of dots, three dots of the first plurality of dotsalternating with one or two dots of the second plurality of dots, fourdots of the first plurality of dots alternating with one, two, or threedots of the second plurality of dots, or combinations thereof.
 8. Theroofing material of claim 1, wherein the first plurality of dots of thefirst adhesive and the second plurality of dots of the second adhesiveapplied along the surface of the shingle stock comprise varying shapes,sizes, or combinations thereof.